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2012/MAG/WKSP/006

Remanufacturer of Engine and Engine Components

Submitted by: Motor Teknologi & Industri (MTI)

Workshop on Remanufactured GoodsKuala Lumpur, Malaysia

22-23 October 2012

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Motor Teknologi & Industri Sdn Bhd(626311‐M)A Member Of 3Q Berhad

www.mti-reman.com

REMANUFACTURER OF ENGINE & ENGINE COMPONENTS

3Q BERHAD BUSINESS AREAS

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ENERGY MRO ASSET MANAGEMENT REMANUFACTURING

Energy solutions provider

Provision of maintenance, repair and overhaul of marine,  land & 

industrial application

Managing of assets to ensure availability for 

operations 

Remanufacturing of engine components, 

engines, land transport and equipment

B U S I N E S S U N I T 

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MOTOR TEKNOLOGI & INDUSTRI SDN BHD

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Date incorporated: 27th Aug 2003

Commenced operations: 1st April 2005

Staff strength: 56

1. Remanufacturing of engines for various applications

2. Precision machining and remanufacturing of engine component

3. Vehicle refurbishment with remanufacturing elements

4. Commercial & industrial equipment refurbishment

5. Asset Maintenance

MTI BUSINESS AREAS

ACCREDITATION AND CERTIFICATION

Tognum Asia Ptd Ltd Tognum AG, Germany

Mercedes Benz MalaysiaMS ISO 9001 : 2008 REG. NO. AR3734

Malaysian State Technical Airworthiness Authority

1. Certified Service Dealer for DDC, OM and MTU engines from Tognum Asia Ptd Ltd

2. Certified engine component remanufacturing center for MTU engines from Tognum 

AG, Germany

3. Certified Engine Refurbishing Plant from Mercedes‐Benz Malaysia

4. Approved Maintenance Organization from the Directorate General Technical 

Airworthiness

5. Certified ISO 9001:2008 Quality Systems from SIRIM QAS  

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3Q BERHAD BUSINESS FOCUS – THE “PRODUCT”

Mechanical Power

Engine

DRIVING

Power Equipment

Propulsion Equipment

Rotating Equipment

Construction Equipment

Mining Equipment

Marine Power Equipment

Power Generation Equipment

DRIVEN

Mechanical Power System

Transmission System

DRIVEN

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WHAT IS REMANUFACTURING?

REMANUFACTURING is a process of restoring old, used or worn

out asset to As-Good-As-New condition.

A REMANUFACTURED COMPONENT;

• Fulfills a similar function as the original part.

• It is restored from an existing part (core) using standardized

industrial processes in line with specific technical

specifications.

• Is given the same warranty as a new component and is clearly

identified as a remanufactured component.

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REMANUFACTURING vs. OTHERS

Type of Work Purpose Start point Extend of work Methodology

Remanufacturing Extend useful life End of life Component or system level

Extensive product recovery process

Refurbishment / Rebuilt

Extend useful life  Mid lifeor 

End of life

Equipment or vehicle

Complete revamp of systems (internals & externals)

Overhaul Part of maintenance 

cycle

According to OEM service manuals

Component or system level

According to OEM service manuals

Recondition Enhance resale value

Quarter of life Equipment or vehicle

Brings to near‐new look & feel 

only

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Cylinder head

Camshaft

Crankshaft

Crankcase

Cylinder head

Connecting Rod

Piston

ENGINE SYSTEM

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MTI REMANUFACTURING PROCESS

TESTING & COMMISSIONING

SKILL AND COMPETENCY

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Remanufacturing

Refurbishment

Recondition

General

Skill & Competency

High

Low

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MULTI SECTORS CAPABILITIES

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Marine

2006                              

Marine

2007                      

Land Transport

Marine

2008                    

Land Transport

Marine

2011                   

Land Transport

Industrial

Marine

2010                              

Land Transport

Industrial

Marine

2009                              

Land Transport

Industrial

YEAR

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Soda BlastingCleaning

Precision Machining Center 

Crankcase machiningCNC Machining

REMANUFACTURING FACILITY

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REMANUFACTURING FACILITY

Engine Testing

Crankshaft machining

Cylinder head remanufacturing

Completed engines

Engine assembly

Cylinder Head Reman Crankcase machining

Crankshaft machiningBefore After

REMANUFACTURING EXPERIENCE

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PRASARANA IVECO engines for buses

BEFORE AFTER

MMEAMarine Generators

REMANUFACTURING EXPERIENCE

TNBLand Rover Defender

BEFORE AFTER

TNB Mobile Generator Set 

REMANUFACTURING EXPERIENCE

ARMYMercedes Benz 911

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Wirtgen Malaysia 

Cold Milling Machine

Malaysia Airports Berhad

Airport Fire Tender

REMANUFACTURING EXPERIENCE

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BENEFITS OF REMANUFACTURING

1. Cost savings – extend the useful life of assets & reduce the need for new purchase

2. Remanufacturing is a viable industry to develop Small & Medium Size Enterprises (SME) infrastructure requirements as well as extending the life of their assets

3. Remanufacturing as a green technology that re‐uses materials and machined to OEM specifications

4. Remanufacturing can be applied at a component level as well as full built up equipment

5. Provides security of supply of parts to asset owners

6. Allows for high‐technology maintenance companies to be able to support OEM products beyond its useful life and better manage obsolescence management

7. Will create jobs for the vocational communities both in mechanical and electrical engineering, enhance skill to expertise level  and hence creating a multiplier effect in the economy

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S4000 Cylinder Head & Crankcase

Remanufacturing Project

Brief On Remanufacturing Scope Of Work

• A 26 step Remanufacturing process (compared to 4 steps in overhaul)• Return a used cylinder head to zero hours with a warranty to match• Over 3,000 units produced with zero defects in the field

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S4000 Cylinder Head Valve Seat

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S4000 Crankcase Remanufacturing

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Evolution of the S4000 Cylinder Head Remanufacturing Machining Process

Valve seat machine Hand tool Factory 

toolsSpecial tools

Limited capability in cutting valve

seat

Factory standard

machine for repair

Cutting of valve seat and

guide simultaneously

by using conventional

reamer

2009 2009 2010 2011

State of the art tool in

accordance to factory

standard.Utilizing

different holder and cooling

system

Critical tolerance:  i.  Valve seat angle 0‐30min toleranceii. Valve seat round out max 0.04mm

CHALLENGES

1) Local technical skill

2) Certification by independent body

3) Market acceptance for remanufactured goods

4) Design for remanufacturing products

5) Reverse logistics – core collection

6) Core usability for remanufacturing

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Q & A